Exposure device and method

ABSTRACT

An exposure device includes a laser source, a first spatial light modulator, a second spatial light modulator and a controller. The laser source is provided for emitting a laser. The first spatial light modulator is irradiated by the laser and used for modulating the phase of the laser irradiated on the first spatial light modulator before reflecting the laser. The second spatial light modulator is irradiated by the laser reflected from the first spatial light modulator and used for modulating the amplitude of the laser irradiated on the second spatial light modulator before reflecting the laser. The laser reflected by the second spatial light modulator is irradiated on a photoresist layer to form an exposure pattern.

BACKGROUND Technical Field

The present disclosure relates to a semiconductor manufacturing device and more particularly relates to an exposure device and method.

Description of Related Art

Photolithography etches and forms a geometric structure on a photoresist layer by exposure and development, and then transfers the pattern formed on a mask to a substrate by etching, wherein the substrate is a silicon wafer or silicon carbide wafer commonly used in semiconductors or a printed circuit board generally used in electronic components. During the manufacturing process, the mask is one of the important components to determine the exposure pattern. However, the mask needs to go through complicated procedures such as design, testing and verification, which may take several months to complete, and thus prolonging the manufacturing process of the semiconductor components.

In order to overcome the problems of the mask, maskless lithography gradually gains favour in the market. As the name suggests, maskless lithography does not use any for exposure in order to form a pattern by the photoresist, thus omitting the mask and achieving the effect of maskless exposure. At present, maskless lithography is widely used in the production for small quantity and diverse variety of components, such as inductors, passive components, microelectromechanical systems (MEMS), etc.

In general, traditional common maskless exposure machines generate exposure patterns on the photoresist layer through a liquid crystal on silicon (LCOS) device or a digital micromirror device (DMD), but such method has the following drawbacks. For example, the liquid crystal modulation speed of LCOS is slow and the method requires a long exposure time, which does not meet the market requirements for the production of semiconductor components.

With reference to FIGS. 1A and 1B for the schematic views of developing a photoresist layer using the digital micromirror device (DMD) after exposure, the photoresist layer 11 is disposed on a wafer 10, and the digital micromirror device (DMD) is used to perform the exposure to a predetermined area 13 of the photoresist layer 11. In FIG. 1B, after the development, a part of the photoresist layer 11 is removed to form a pattern 12. However, due to diffraction, the light is often not 100% concentrated in the area to be exposed, and the area not to be exposed is often partially irradiated (especially near the edge of the area to be exposed). Therefore, the actually formed pattern 12 has an edge 14 unlike the one of the predetermined area 13 perpendicular to the wafer 10, but the formed pattern 12 is deviated. The edge 14 may be an inclined plane and the area of edge 14 may be smaller than or greater than the predetermined area 13, so that the pattern 12 cannot be accurately formed at the predetermined position. In other words, if the DMD is used for exposure, the phase cannot be changed, so that it will be unable to set the shape of the pattern accurately or sharply, and the development result will not be as expected (or will have a poor yield), especially in thick photoresist exposure.

Therefore, how to solve the problem is worthy of consideration by related manufacturers and those having ordinary skill in the art.

SUMMARY

In view of the drawbacks of the related art, it is a primary objective of the present disclosure to provide an exposure device that controls a laser by the method of adjusting the phase and amplitude to achieve the effects of controlling the pattern more precisely or sharply and overcoming the drawbacks of the traditional maskless exposure which can only adjust the amplitude.

To achieve the aforementioned and other objectives, this disclosure discloses an exposure device for projecting a laser on a photoresist layer, and the exposure device includes a laser source, a first spatial light modulator, a second spatial light modulator and a controller. The laser source is provided for emitting a laser. The first spatial light modulator is irradiated by the laser and includes a plurality of first pixels, each being used for reflecting the laser after the phase of the laser irradiated on the first spatial light modulator is modulated first pixel. The second spatial light modulator is irradiated by the laser reflected by the first spatial light modulator and includes a plurality of second pixels, each being used for reflecting the laser after the amplitude of the laser irradiated on the second spatial light modulator is modulated. Wherein, the laser reflected by the second spatial light modulator is irradiated on the photoresist layer to form an exposure pattern, and the exposure pattern includes a plurality of third pixels, and the first pixel, the second pixel, and the third pixel correspond with one another.

This disclosure further provides an exposure method, including the steps of:

-   -   (a) emitting a laser to a first spatial light modulator, wherein         the first spatial light modulator includes a plurality of first         pixels;     -   (b) using the first spatial light modulator to change the phase         of the laser modulated by each of the first pixels;     -   (c) using the first spatial light modulator to irradiate the         laser to a second spatial light modulator after the phase of the         laser is modulated, wherein the second spatial light modulator         includes a plurality of second pixels;     -   (d) using the second spatial light modulator to change the         amplitude of the laser modulated by the second pixel; and     -   (e) using the second spatial light modulator to irradiate the         laser to a photoresist layer to form an exposure pattern after         the amplitude of the laser is modulated, wherein the exposure         pattern includes a plurality of third pixels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are schematic views showing the exposure and development of a photoresist layer using MDM;

FIG. 2A is a schematic view of an exposure device of this disclosure;

FIG. 2B is a schematic block diagram of an exposure device of this disclosure;

FIG. 3A is a schematic view of a first spatial light modulator which is a liquid crystal on silicon (LCOS) device in accordance with some embodiment of this disclosure;

FIG. 3B is a schematic perspective view of a first spatial light modulator of this disclosure;

FIG. 4 is a schematic perspective view of a second spatial light modulator of this disclosure;

FIG. 5 is a schematic view of forming an exposure pattern of this disclosure;

FIG. 6A is a schematic view of a first pixel of this disclosure;

FIG. 6B is a schematic view of forming an exposure pattern formed by a laser of this disclosure;

FIG. 6C is a schematic view showing the light intensity of a third pixel at a time point of this disclosure;

FIG. 7A is a flow chart of an exposure method of this disclosure; and

FIG. 7B is a flow chart of detecting the phase and light intensity in the exposure method of this disclosure.

DESCRIPTION OF THE EMBODIMENTS

This disclosure will now be described in more detail with reference to the accompanying drawings that show various embodiments of this disclosure.

This disclosure provides an exposure device and an exposure method, and uses a spatial light modulator to modulate the phase and amplitude of a laser, and makes use of the lasers with different phases and amplitudes to interfere and offset each other to form a more accurate exposure pattern. With reference to FIGS. 2A, 2B and 7A for the schematic views of an exposure device 100, the structure of the exposure device 100 and an exposure method of this disclosure respectively, the exposure device 100 includes a laser source 110, a beam expander 112, a first spatial light modulator 120, a second spatial light modulator 130, a sensor 140, a controller 150 and a projection lens 160.

Firstly, the Step S11 is carried out to emit a laser 111 to a first spatial light modulator 120. The laser source 110 as described in the Step S11 is provided for emitting the laser 111. The first spatial light modulator 120 is installed on the path of the laser 111 and irradiated by the laser 111. The beam expander 112 is installed between the laser source 110 and the first spatial light modulator 120 and disposed on the path of the laser 111, so that the laser 111 passes through the beam expander 112 and irradiates the first spatial light modulator 120. When the laser 111 passes through the beam expander 112, the irradiation radius of the laser 111 will be expanded to increase the area of the first spatial light modulator 120 which is irradiated by the laser 111. In some embodiment, when the laser 111 passes through the beam expander 112, the laser 111 will cover the entire first spatial light modulator 120. In this embodiment, the first spatial light modulator 120 is a liquid crystal on silicon (LCOS) device, so that the first spatial light modulator 120 includes a plurality of first pixels 201, each being used for reflecting the laser 11 after the phase of the laser 111 irradiated on the first spatial light modulator 120 is modulated, and the phase of the reflected laser 111 a can be changed. Then, Step S12 is proceeded, and the first spatial light modulator 120 changes the phase of the laser modulated by each first pixel 201.

With reference to FIG. 3A for the schematic view of a liquid crystal on silicon (LCOS) device uses as the first spatial light modulator in accordance with some embodiment of this disclosure, the liquid crystal on silicon (LCOS) device used as the first spatial light modulator 120 includes a substrate layer 210, a complementary metal oxide semiconductor (CMOS) layer 220, a reflective layer 230, two alignment layers 240, 240′, a liquid crystal layer 250, a transparent electrode layer 260 and a cover glass 270. The CMOS layer 220 includes a CMOS circuit layer 221 and a plurality of pixel electrodes 222, and the reflective layer 230 is disposed on the CMOS layer 220, and the alignment layer 240 is disposed above the reflective layer 230, and the liquid crystal layer 250 is disposed between the two alignment layers 240, 240′. The transparent electrode layer 260 is disposed above the alignment layer 240′, and the transparent electrode layer 260 has a plurality of transparent electrodes (not shown in the figure), each being configured to be corresponsive to one of the pixel electrodes 222. In other words, the transparent electrode and the pixel electrode 222 are configured in pairs. The cover glass 270 covers the top of the transparent electrode layer 26 for protecting each component in the liquid crystal on silicon (LCOS) device, in addition to receiving external light. Further, the top of the cover glass 270 has an anti-reflective layer 280 such as an anti-reflective coating.

With reference to FIG. 3B for the perspective view of a liquid crystal on silicon (LCOS) device uses as a first spatial light modulator 120 of this disclosure, the viewing plane of the liquid crystal on silicon (LCOS) device is divided into a plurality of first pixels 201, each being configured to be corresponsive to one of the pixel electrodes 222 and the transparent electrode. In this embodiment, the liquid crystal on silicon (LCOS) device receives an external control signal through the CMOS circuit layer 221 to control the electrical property of the transparent electrode on the pixel electrode 222 and the transparent electrode layer 260, so that the liquid crystal 251 in the liquid crystal layer 250 corresponding to each pixel electrode can rotate, and after light enters into the liquid crystal on silicon (LCOS) device, the light is affected by the rotated liquid crystal 251 and the phase of the light will be changed. In addition, the direction of the liquid crystal 251 corresponding to each first pixel 201 is controlled by the pixel electrode 222 and the transparent electrode, so that the phase of the light emitted by each first pixel 201 can be controlled.

In FIGS. 2A and 7A, the Step S13 is carried out to irradiate a laser 111 to the second spatial light modulator 130 after the first spatial light modulator 120 modulates the phase of the laser 111 a. The second spatial light modulator 130 is installed on the path of the laser 111 a reflected by the first spatial light modulator 120. In addition, the second spatial light modulator 130 includes a plurality of second pixels, each second being used for reflecting the laser 111 a after the amplitude of the laser 111 a is modulated. In this embodiment, the second spatial light modulator 130 is a digital micromirror device (DMD) that can reflect the laser 111 a, and the amplitude of the reflected laser 111 b will be changed. Therefore, when the Step S14 is carried out, the second spatial light modulator 130 changes the amplitude of the laser 111 b modulated by the second pixel.

With reference to FIG. 4 for the schematic view of a second spatial light modulator in accordance with some embodiment of this disclosure, the second spatial light modulator 130 further includes a plurality of second pixels, which are micromirrors 320 in this embodiment, and these micromirrors 320 are installed on a substrate 310. In this embodiment, each micromirror 320 corresponds to one of the first pixels 201 on the first spatial light modulator 120 (as shown in FIG. 3B). Each micromirror 320 can control and change an angle, so that the micromirror 320 has the ON or OFF effect. For example, when the angle relative to the horizontal plane is positive 12°, the micromirror 320 is turned on, and when it is negative 12°, the micromirror 320 is turned off, and the frequency of turning on/off the micromirror 320 can also be controlled. By adjusting the different frequency of switching on and off the micromirrors 320, the laser 111 a can be reflected, so that the laser 111 a reflected by the micromirror 320 with different switching frequencies can accumulate different energies, so as to the effect of adjusting the amplitude (i.e.: the intensity) of the laser 111 a irradiated on the photoresist layer 20. After being reflected by the second spatial light modulator 130, the laser 111 b is projected onto the photoresist layer 20 through the projection lens 160 to form an exposure pattern 400 as shown in FIG. 5 .

In FIGS. 2A and 7A, the Step S15 is carried out, and the laser 111 b modulated by the second spatial light modulator 130 is irradiated on the photoresist layer 20 to form an exposure pattern 400. After the laser passes through the first spatial light modulator 120, the phase of the laser emitted by each first pixel 201 can be adjusted. In addition, the laser passes through the second spatial light modulator 130, the adjusted laser is irradiated on the photoresist layer 20 with an intensity distribution, so as to have bright and dark distributions on the surface of the photoresist layer 20 and form an exposure pattern 400 as shown in FIG. 5 .

With reference to FIG. 5 for the schematic view of the exposure pattern 400, the exposure pattern 400 can be regarded as being formed by a plurality of third pixels 401 arranged in an array, and the third pixel 401 includes a third dark-area pixel 410 and a third bright-area pixel 420, and each third pixel 401 corresponds to one of the first pixels 201 on the first spatial light modulator 120 and one of the micromirrors 320 on the second spatial light modulator 130.

The first pixel 201 corresponding to the third pixel 401 includes a plurality of first dark-area pixels and a plurality of first bright-area pixels, and the third dark-area pixel 410 corresponds to the first dark-area pixel, and the third bright-area pixel 420 corresponds to the first bright-area pixel. The phases of the laser modulated by at least two first bright-area pixel of the adjacent first dark-area pixels differ by 180° with each other.

With reference to FIG. 6A for the schematic view of a first pixel, only three first pixels 201 are shown in FIG. 6A for simplicity, and the first pixel includes one first dark-area pixel 2011 and two adjacent first bright-area pixels 2012 a, 2012 b. In this embodiment, the first bright-area pixels 2012 a, 2012 b are disposed on the left and right sides of the first dark-area pixel 2011 respectively. After the first bright-area pixels 2012 a, 2012 b modulate the lasers, the phases of the modulated lasers differ by 180° with each other. In other words, the phases of the lasers modulated by the first bright-area pixel 2012 a, 2012 b differ by 180° with each other.

With reference to FIG. 6B for the schematic view of the exposure pattern formed by the laser, the laser reflected by the first bright-area pixel 2012 a is projected onto the third bright-area pixel 420, and the laser reflected by the first bright-area pixel 2012 b is projected onto the third bright-area pixel 420′.

With reference to FIG. 6C for the schematic view showing the light intensity of the third pixel at a time point, the curve 601 shows the light intensity of the laser reflected by the first bright-area pixel 2012 a and projected onto the third bright-area pixel 420. The curve 602 shows the light intensity of the laser reflected by the first bright-area pixel 2012 b and projected onto the third bright-area pixel 420′. Due to the light diffraction, a part of the laser is projected onto the third dark-area pixel 410. The laser reflected by the first bright-area pixel 2012 a, 2012 b has a phase difference of 180°, so that the phase of the laser projected onto the third bright-area pixels 420, 420′ are in opposite states, and the lasers diffracted onto the third dark-area pixel 410 will be interfered and offset with each other due to the lasers reflected by the first bright-area pixels 2012 a, 2012 b. In this way, the light projected on the third dark-area pixel 410 can be effectively reduced, and further, when the exposure pattern is formed, the distinction between the third bright-area pixel 420 and the third dark-area pixel 410 can be clearer. The micromirror 320 corresponding to the third pixel 401 of the third dark-area pixel 410 has a deflection angle, so that the reflected laser will not irradiate on the third dark-area pixel 410. On the contrary, the deflection angle of the micromirror 320 corresponding to the third pixel 401 of the third bright-area pixel 420 can irradiate the reflected laser on the third bright-area pixel 420.

With reference to FIGS. 2A and 7A again, a sensor 140 of one of the embodiments is installed between the second spatial light modulator 130 and the photoresist layer 20 and provided for detecting the phase and light intensity of the laser 111 b emitted from the second spatial light modulator 130 in the Step S16. In addition, a projection lens 160 is installed on the path of the laser 111 b reflected from the second spatial light modulator 130, and the laser 111 b passes through the projection lens 160 and then projects onto the photoresist layer 20 to form the exposure pattern 400 on the photoresist layer 20.

In some embodiment, the sensor 140 includes a plurality of beam splitters 143, 143′, a light intensity sensor 142, and a phase sensor 141. The beam splitter 143′ is installed between the second spatial light modulator 130 and the projection lens 160 and provided for dividing the incident laser 111 b into a first laser 111 b′ and a second laser 111 b″. Further, the ratio of the light intensity of the first laser 111 b′ to the light intensity of the second laser 111 b″ is 99:1, i.e. the beam splitter 143′ will project 1% of the divided laser into a light intensity sensor 142 and a phase sensor 141. In some embodiment as shown in FIG. 2A, the second laser 111 b″ is split by a beam splitter 143, and projected to light intensity sensor 142 and the phase sensor 141. The sensor 140 receives the second laser 111 b″ through the light intensity sensor 142 and the phase sensor 141 to generate a sensing signal.

With reference to FIGS. 2B to 7B, FIG. 7B shows a flow chart of detecting the phase and light intensity in the exposure method of this disclosure, and the controller 150 is electrically connected to the laser source 110, the first spatial light modulator 120, the second spatial light modulator 130 and the sensor 140. The controller 150 is a programmable logic controller or a computer device with a control program. The controller 150 is provided for receiving a sensing signal, and controlling the light intensity and phase of the laser outputted by the laser source 110 according to the sensing signal, and the control method includes the following steps:

S161: The beam splitter 143′ is used to divide the laser 111 b into a first laser 111 b′ and a second laser 111 b″, wherein the first laser 111 b′ is the laser irradiated on the photoresist layer 20 as described in the Step S15.

S162: The second laser 111 b″ is projected on a light intensity sensor 142 and a phase sensor 141, and another beam splitter 143 is used to drive the second laser 111 b″ to enter into the light intensity sensor 142 and the phase sensor 141 separately.

S163: The light intensity sensor 142 detects the light intensity of the second laser 111 b″.

S164: The phase sensor 141 is used to detect the phase of the second laser 111 b″.

S165: The first light modulator 120 and the second light modulator 130 are controlled according to the phase and light intensity of the second laser 111 b″, and the formed exposure pattern 400 is corrected.

In some embodiment, the steps S15 and S16 (which are the steps S161˜S165) are performed synchronously. While the exposure pattern 400 is being formed, the exposure pattern 400 formed by the laser can be dynamically adjusted through the steps S161˜S165, and the exposure pattern 400 can be continuously corrected during the exposure process, further ensuring that the exposure pattern 400 matches the expected pattern.

More specifically, the controller 150 compares the laser parameter measured by the sensor 140 with a predetermined laser parameter, and if the measured laser parameter does not match the predetermined laser parameter, the controller 150 will control the laser source 110 to adjust the light intensity and phase of the incident laser, until the laser parameter measured by the sensor 140 matches the predetermined laser parameter.

In some embodiment, the controller 150 further includes an input interface 151 provided for an operator to enter a predetermined laser parameter. In addition, the input interface 151 is also provided for the operator to input a desired exposure pattern, so that the controller 150 can further operate the first spatial light modulator 120 and the second spatial light modulator 130 to form the desired exposure pattern on the photoresist layer 20 according to the data of inputted exposure pattern.

The exposure device and method of this disclosure have the advantages of forming a more precise or sharp exposure pattern, improving the yield of development, and overcoming the drawbacks of the related art by means of modulating the of the phase and amplitude of the laser and using the mutual interference and offset of the laser between pixels.

Although the invention has been disclosed and illustrated with reference to particular embodiments, the principles involved are susceptible for use in numerous other embodiments that will be apparent to persons skilled in the art. This invention is, therefore, to be limited only as indicated by the scope of the appended claims. 

What is claimed is:
 1. An exposure device, configured for projecting a laser onto a photoresist layer, and the exposure device comprising: a laser source, for emitting a laser; a first spatial light modulator, irradiated by the laser, and comprising a plurality of first pixels, each first pixel being used for reflecting the laser after the phase of the laser irradiated thereon is modulated; a second spatial light modulator, irradiated by the laser reflected by the first spatial light modulator, and comprising a plurality of second pixels, each second pixel being used for reflecting the laser after the amplitude of the laser irradiated thereon is modulated; a controller, electrically coupled to the laser source, the first spatial light modulator and the second spatial light modulator for controlling the laser source, the first spatial light modulator and the second spatial light modulator; and a sensor, installed between the second spatial light modulator and the photoresist layer, and electrically coupled to the controller; wherein, the laser reflected by the second spatial light modulator irradiates on the photoresist layer and forms an exposure pattern, and the exposure pattern comprises a plurality of third pixels, and the first pixel, the second pixels correspond to the third pixels respectively; wherein, the sensor comprises a beam splitter, a light intensity sensor, and a phase sensor, and the beam splitter is installed between the second spatial light modulator and the photoresist layer and provided for dividing the incident laser into a first laser and a second laser, and the first laser is incident on the second spatial light modulator, and the second laser is incident on the light intensity sensor and the phase sensor.
 2. The exposure device according to claim 1, wherein the first spatial light modulator is a liquid crystal on silicon (LCOS) device.
 3. The exposure device according to claim 1, wherein the second spatial light modulator is a digital micromirror device (DMD), and the digital micromirror device (DMD) comprises a plurality of micromirrors used as the second pixels.
 4. The exposure device according to claim 1, wherein the second spatial light modulator is a liquid crystal on silicon (LCOS) device.
 5. The exposure device according to claim 1, wherein the ratio of the light intensity of the first laser to the light intensity of the second laser is 99:1.
 6. The exposure device according to claim 1, further comprising a projection lens installed between the second spatial light modulator and the photoresist layer, wherein the projection lens focuses the laser reflected by the second spatial light modulator and irradiates the laser on the photoresist layer to form the exposure pattern.
 7. The exposure device according to claim 1, wherein the third pixel comprises a plurality of third dark-area pixels and a plurality of third bright-area pixels, and the first pixel comprises a plurality of first dark-area pixels and a plurality of first bright-area pixels, and the third dark-area pixels correspond to the first dark-area pixels respectively, and the third bright-area pixels correspond to and the first bright-area pixels respectively, and the phases of the lasers modulated by at least two of the first bright-area pixels adjacent to the first dark-area pixel differ by 180°.
 8. The exposure device according to claim 1, further comprising a beam expander disposed on the path of the laser, and the laser passes through the beam expander to irradiate the first spatial light modulator.
 9. An exposure method, comprising the steps of: (a) emitting a laser to a first spatial light modulator which includes a plurality of first pixels; (b) using the first spatial light modulator to change the phase of the laser modulated by each of the first pixels; (c) using the first spatial light modulator to irradiate the laser onto a second spatial light modulator after the phase of the laser is modulated, wherein the second spatial light modulator comprises a plurality of second pixels; (d) using the second spatial light modulator to change the amplitude of the laser modulated by the second pixel; (e) projecting the laser to a photoresist layer to form an exposure pattern after the second spatial light modulator modulates the amplitude, wherein the exposure pattern comprises a plurality of third pixels; and (f) detecting the phase and light intensity of the laser coming from the second spatial light modulator; wherein, the Step (f) and Step (e) are performed synchronously; wherein, the first pixel, the second pixel and the third pixel correspond with one another: wherein the Step (f) further comprises the steps of: (f1) dividing the laser into a first laser and a second laser by a beam splitter; (f2) projecting the second laser towards a light intensity sensor and a phase sensor; (f3) using the light intensity sensor to detect the light intensity of the second laser; (f4) using the phase sensor to detect the phase of the second laser; and (f5) controlling the first light modulator and the second light modulator according to the phase and light intensity of the second laser.
 10. The exposure method according to claim 9, wherein the first spatial light modulator is a liquid crystal on silicon (LCOS) device.
 11. The exposure method according to claim 9, wherein the second spatial light modulator is a digital micromirror device (DMD), and the digital micromirror device (DMD) comprises a plurality of micromirrors used for the second pixels.
 12. The exposure method according to claim 9, wherein the second spatial light modulator is a liquid crystal on silicon (LCOS) device. 